Method of making armatures



Dec. 3, 1929. .v. G. APPLE 1,738,166

METHOD OF MAKING ARMATURES Original Filed Nov. 18, 1927 5 Sheets-Shem; 1

Fi57 7 2 Fig--21- D82. 3, 1929. V AP LE 1,738,166

METHOD OF MAKING ARHATURES Original' Filed Nov 1e, 1927 5 Sheets-Sheet 2E v a; 46

V. G. APPLE METHOD OF MAKING ARMATURES Dec; 3, 1929.

Original Filed Nov. 18, 1927 .5 Sheets-Sheet 3 'i flzda.

Ill

. lNVE/VTOR.

Dec. 3,1929. I v.0. APPLE 1,733,166

v METHOD OF MAKING ARMATURES Original Filed Nov. 18, 1927 5 Sheets-Sheet4 Fig-5m5- 83 I 5.9- Z 5. 28

g5 g {g I 78 -90 32 3/ My 77 k! Deg. 3, 1929. v. s. APPLE 1,738,165

us'rnon or MAKING ARIATURES Original Filed Nov. 18, 1927 5 Sheets-Sheet5 .J As

Patented Dec. 3, 1929 UNITED STATES VINCENT G. API LE, OI DAYTON, OHIOMETHOD OF MAKING ARMATURES Original application filed November 18, 1927,Serial No. 234,158 Divided and this application filed October 26, 1928.Serial No. 315,342.

This invention is shown, tho not claimed in my co-pending applicationSerial No. 234,158 of which this application is a division and relatesto bar wound armatures having commutators, and comprises a windingcomposed of loops suitable for radial entry into open core slots, theopen ends of said loops being somewhat prolonged and specially formed sothat the commutator segments are com- 10 posed of pairs thereof.

' An object of my invention is to reduce the.

cost of an armature by eliminating the separately made commutator,thereby reducing the number of parts .and the amount of labor Fig. 2 isa cross section taken at Fig. 1.

Fig. '3 shows the bar Fig. 1 with portions cut away. i

Fig. 4 shows a bar Fig. 3 after it has been 30 bent to form one loop ofa lap winding.

Fig. 5 is an end view of Fig. 4. Fig. 6 shows a bar Fig. 3 after it hasbeen bent to form one loop of a wave winding. Fig. 7 is an end view ofFig. 6. Fig. 8 shows several loops of a lap winding assembled in acore.'

Fig. 9 shows several loops of a wave winding assembled in a core. I

Fig. 10 shows a completed armature, partly 40 in section. 3 Fig. 11 is across section taken at 11-11 Fig. 2.

Fig. 12 is a cross section taken at 12- -12 Fig. 2.

binding means applied to loops made accord- 50 ing to my invention.

Fig. 13 shows how commutator lugs are Fig. 15 is a cross section ofrectangular bar stock which I may employ.

Fig. 16 is a cross section thru either of the conductor bars resultingwhen rectangular stock Fi 15 is used and cut away as in Fig. 3.

Fig. 1 is a fragmentary end View of a core having rectangular windingslots. 1 v

Fig. 18 is an outline of a pad which may be used to increase thethickness of a commutator segment.

Fig. 19 shows how commutator lugs of rectangular cross section may becombined with a pad to make a relatively thick commutator segment. I

Fig. 20 shows how commutator lugs of 55 wedge shaped cross section maybe combined with a pad to make a'relatively thick wedge I shapedcommutator segment.

Fig. 21 is a cross section thru Wire from which my winding units may bemade.

Fig. 22 shows a length of wire Fig. 21 bent back upon itself to hairpinform.

Fig. 23 is a plan view of a complete loop made from wire Fig. 21.

Fig. 24 is an end view'of Fig. 23.

Fig. 25 shows two loops placed in a core.

Fig. 26 shows a completed armature, partly in section, wound with wireloops Figs. 23 and 24.

Fig. 27 is a cross section taken thru a mold immediately above the endsof the commutator lugs.

Fig. 28 is a cross section thru another form of wire from which loopsmay be made.

Fig. 29 shows a step in the method of form ing wire Fig. 28 into a loop.

Fig. 30 is a plan View of a loop formed from wire Fig. 28.

Fig. 31 is an end View of a loop formed from wire Fig. 28.

Fig. 32 shows two loops Fig. .30 in a core.

Fig. 33 is a top View of a mold used to bind the ends of loops Fig. 30together.

Fig. 34 shows a complete armature wherein loops Fig. 30 have been used.

Fig. 35 is a cross section thru a'bar of stock which is but slightlywedgev shaped.

Fig. 36slfows the mannerin which a bar Fig. 35 may besplit lengthwise. I

Fig. 37 shows how the ends of bars shown in Fig. 36 may be paired.

Fig. 38 shows how winding units may be economically cut from sheetstock.

Fig. 39 is a winding unit as it appears when out as in Fig. 38.

Fig. 40 shows how units Fig. 39 are offset.

Similar numerals refer to similar parts thruout the several views.

Heretofore bar wound armatures of the open slot type have usually beenmade by providing loo s of bar stock or wire and radially entering t eseloops into the open core slots, then providing a separate commutator andjoining the open ends of the loops to bars of the commutator bysoldering. The volume of current carried by these bar windings isusually large and frequently the solder is melted and the usefulness ofthe armature destroyed.

This. together with the fact that the cost of separately producing aconventional commutator is considerable, and the labor incident tojoining the loop ends to the commutator bars is costly, makes thehereinafter described method of great value both as to cost anddependability.

A segment of a commutator is preferably wedge shaped, and since thepresent invention contemplates forming a commutator segment and a turnof the winding integral, a simple way to put the invention to practiceis to use a core having wedge shaped winding slots. In this way stock ofsuitable cross section to fit a winding slot may be suitable also for acommutator segment. As one means to'thus carry out my invention Iprovide lengths of bar stock Fig. 1 of a cross section Fig. 2, then cutaway portions 20 and 21 and cut notches 26 and 27 Fig. 3. leaving aconductor bar 22 adapted to occupy a position in the outer layer of thewinding, a conductor bar 23- adapted to occupy a position in the innerlayer of the winding connected as at 30, and two lugs 24 and 25 eachsuitable to compose half the thickness of a commutator segment.

Segments of conventional commutators are frequently composed of severalcircumferentially adjacent layers, so also in the present invention alug 24 and a lug 25 are placed circumferentially adjacent in electricalcon tact and held by a commutator segment binding means which impingeson notches 26 and 27. A cross section thru outer conductor bar 22 isshown at 28 Fig. 11 and a cross section thru inner conductor bar 23 isshown at 29 Fig. 12. The cross sectional areas of Fi 11 and Fig. 12 aresubstantially equal.

fter lengths of'stock have been cut away and notched as shown in Fig. 3they are bent to compose loops. If a lap winding is de-- sired they arebent as in Fig. 4 and end view Fig. 5, while if awave winding is desired'thtiy are bent as in Fig. 6 and end view Fig. 7.

g. 8 shows several loops of a lap winding in place in a core 33 whileFig. 9 shows several loops of a wave winding in place in another core33. The purpose of these figures is to show how a continuous circuit maybe provided by placing a commutator lug 24 circumferentially adjacent toa commutator lug 25, two such lugs in electrical contact joiningadjacent loops of the circuit and together composingone commutatorsegment. Other requirements of common practice must be met, such ashaving the core slots lined with insulating material, keeping the outerand inner layers of the winding electrically separated, etc.

When a'number of loops equal to the number of slots have been assembledin a core, pairs of commutator lugs must be held in intimate electricalcontact, one member of a pair with the other, to compose commutatorsegments, and the segments must be mechanically bound together, thoelectrically. separated from each other, to compose a commutator.

Spacers 34 of insulating material may be inserted to separate theseveral segments but must not be placed between the two lugs whichtogether compose a segment. Spacers 34 may, however, be eliminated in amanner hereinafter described relative to Fig. 27.

A preferred binding means is shown in Fig. 10 where molded insulatingmaterial 31 surrounds the conductor bars and impinges on the notches 26and 27 to bind the commutator segments together. Any suitable insulatingmaterial may be used, as may any suitable mold, a requirement being thatthe commutator lugs may be subjected to inward radial pressure, or thatthey may be otherwise held' to keep them in intimate contact whilemolding is taking place, and while the drawing shows the entire windingcovered with insulating material, an economy may be effected by soarranging the mold as to permit insulating material to surround thecommutator end of the armature only, and when the armature is to run atrelatively lqyy speed such modification may be justifia e.

Instead of using molded insulation as a binding means, the conventionalcommutator binding means may be employed. By cutting and notching alength of stock as in Fig. 13, instead of as in Fig. 3, a conventionalcommutator binding means shown in Fig. 14 may be used. In Fig.13 the lug35 is notched as at 36 and 37 and the lug 38 is notched as at 39 and 40.In Fig. 14 a nut 41 draws together the beveled head 42 of sleeve 43 andthe beveled washer 44 against insulation 45, after the manner practicedin building ordinary commutators.

In the foregoing my improved bar winding has been described as itapplies to cores having wedge shaped winding slots, but a windingapplicable to slots of other cross section may profitably embod myimprove-- ments. For instance, if bar ig. 1 were of a cross section asat 46 Fig. 15. it could be cut away and notched as in Fig. 3 and bent asin Figs. 4 and 5, or as in Figs. 6 and 7, or an outline as shown in Fig.3 could be punched directly from flat sheet stock.

The conductor bars 21 and 22 would then be of rectangular cross sectionas at 47 Fig. 16 and could readily be assembled in a core 49 havingrectangular slots as at 48 Fig. 17, but in such a case the lugs 24 and25 should preferably be changed from their rectangular cross section 46Fig. 15 to a wedge shaped cross section as at Fig. 2. This 0 uld readilybe accomplished by striking the ugs fiatwise in a die, after which thewinding could be assembled with core 49 and bound together as describedrelative to Figs. 8, 9 and 10.

Where an increased diameter of the comsomewhat increased thickness.This-method of padding may also be used to produce a commutator ofincreased diameter when wedge shaped bar stock and wedge shaped coreslots are used, by adding a'pad of uniform thickness, and of an outline32 Fig. 18, to the wedge shaped lugs 24 and 25 Fig. 20, thus providing athicker segment. In fact a bar Fig. 1 may be of any cross section withinreason, to fit corresponding core slots, if pads are added to thecommutator lugs that will supply the difference between the naturalcross section of a pair of lugs and the desired commutator segment.

The method of making-a unit of my improved winding as disclosed in theforegoing description provided commutator segments of considerableradial depth, so that a com-- mutator so made will admit of theconsiderable reduction in diameter incident to wear I and truing up,giving long life to the armature. But there is a class of armaturessuch. as are used in starting motors of automotive engines and the like,which not being called on for continuous service, are subject -to littlewear, and in such armatures, commutator segments of less radial depthmay be employed. In the following description, which relates to Figs. 21to 27 inclusive, I disclose one method of procedure in applying myimprovements to economically produce such armatures.

\Vire of a cross section 51 Fig. 21 is -pref erably made by passing around wire of standard gauge between rollers, but it may drawn directlyto the shape shown. Thls wire is cut to suitable lengths and each length.is bent double to hairpin form as shown in hairpin. The loop 65 Figs.23 and 24 comprises an outer layer conductor bar 55, an inner layerconductor bar .56 joined at 54 by back lead portions 57 and 58, andfront lead portions 59 and 60 terminating in commutator lugs Gland 62.

Lugs 61 and 62 are produced by striking the free ends of the loop in adie and are not necessarily of greater crossflsectiona'l area than thewire Fig. 21, tho they may be stoved slightly endwise in the die toincrease their cross sectional area. The lugs, however, are

of somewhat greater radial depth than the bars. Grooves 63 and 64are'pressed lengthwise in the sides of lugs 61 and 62 respectively, tohelp increase the radial depth of the lugs, and to provide ledgeswh'ereon the commutator binding means may bear.

F'g. 25 shows two loops 65 laid in the slots of a core66, and the mannerin which one pair of lugs 61 and 62 here come together to continue thecircuit and form one commutator segment is typical of the entirewinding.

When an entire set of loops 65 have been entered into the slots of core-66, the structure is placed in mold 75 where insulatin material 67 maybe molded between and around front lead portions 59 and 60 and betweensegments composed of pairs of lugs 61 and 62, into grooves 63 and 64 tobind the structure together.

Fig. 27 shows a cross section taken thru mold 75 immediately above theends of the commutator segment. The mold consists, in

between segments. composed .of

shaft 71 filling space 72, and to extend thru...

openingsa-73 into pockets 74 to bind the lugs together to form acommutator.

Still another method of procedure to pro-,

'vide a commutator from ciroumferentially adjacent ends of conductorbars, where no great amount of wear is anticipated, is shown anddescribed relative to Figs. 28 to 34 inclu, sive, where a length of wire83; of cross section 95 Fig. 28 is ofi'set as at 76, 77 and 78 Fig. 29forming a leg 79 which later becomes a conductor bar of the inner layerof the winding, a leg 80 which later becomes a conductor bar of theouter layer of the winding and two lugs 81 and 82 which later becomelayers of the cylindrical ring which forms the commutator. Lugs 81 and82 are in alignment inFig. 29.

The bar 83 is next bent to form loop 92 shown in plan view Fig. 30 andend view Fig. 31, where a portion of leg 79 Fig. 29 forms back lead 84and a portion forms front lead 85, the remainder forming inner layerconductor bar 86, and where a portion of leg 80 Fig. 29 forms back lead87 and a portion forms front lead 88, the remainder forming outer layerconductor bar 89. Lugs 81 and 82 are beveled as at 90 and 91respectively for reasons hereinafter disclosed.

Fig. 32 shows two loops 92 laid in the slots of a core 66, two lugs 81and 82 being circumferentially adjacent to form one commutator segmentand to join the two loops shown in continuous circuit. The entirewinding is assembled in the same manner.

After an entire winding is placed in the slots of core 66 the core andwinding are together placed in mold 75, a top view of which is shown inFig. 33 with the armature in place, where insulation may be molded aboutshaft 71 to fill space 72 and extend outwardly between the commutatorsegments as far as tangs 70 of jaws 69 will permit.

Each commutator segment comprises a lug 81 and 82 circumferentiallyadjacent and in electrical contact. A completed armature is shown inFig. 34 where insulation 93 extends between and about front leads and88, between shaft 71 and lugs 81 and 82 and around beveled ends and 91of said lugs to bind the whole together to compose a commutator.

As previously mentioned, loops shown in Figs. 1 to 7 inclusive areapplicable when commutator segments of great radial depth are desired,and loops shown in Figs. 22. 23 and 24 when less radial depthispermissible.

'Loops shown in Figs. 29, 30 and 31 are likewise applicable where nogreatdepth of commutator segment is required, but the latter loops areparticularly suitable when the core contains a large number of aperturesand the commutator therefore a large number of segments, since thegreater the number of winding apertures, the deeper and thlnner theconductor bars become. and the more nearly rectangular is the crosssection of the bar, making it suitable to be placed one bar aboveanother in the same winding aperture with minimum waste of spacetherein.

A loop may be economically provided for an armature having a largenumber of bars,

and consequently having commutator segments which are nearlyrectangularin cross section by splitting a bar of cross section 94 Fig.35 lengthwise as in Fig. 36 to provide legs 96 and 97 of substantiallyequal cross sectional'area, tho the bar 96 is slightly thinner and widerthan the bar 97. The hairpin thus formed may be bent in the form of aloop similar to loop 65, Figs. 28 and 24,

punching parts 100 (see-Fig. 39) from strips' of flat sheet stock, onepart immediately following the other with substantially no waste asshown in Fig. :38. At each stroke of the punch press spots 101 shownshaded in the sheet, may be struck, an edge'102 of a spot being struckharder than the other edge 103, to provide the; wedge shaped crosssection from which the'commutator lugs 24 and 25 are afterwards cut.Offset 30 (see Fig. 40) is then made at the middle portion of each part100 by bending, when these parts will be identical with those shown inFig. 3, after which the procedure is identical with that describedrelative to Figs. 1 to 10 inclusive.

The great diversity of purposes for which dynamo electric machinearmatures are made necessitates a wide range in the character of theirwindings and commutators, and while I have shown several forms in whichmy improved integral winding units may be made, still other andconsiderably modified forms of these units which may be forged, sandcast, die cast, or otherwise fabricated, by new or known methods ofprocedure may be employed to carry out the principles of this inventionwhich consists not so much in the method whereby the loops are made asin the method of making an armature therefrom..

Having described my invention 1 claim- 1. The method of making anarn'lature having an integral commutator and winding which consists ofcutting a plurality of lengths of stock each suitable for a turn of thewinding, forming each piece into a loop comprising a conductor bar ofthe outer layer, a conductor bar of the inner layer and two wedge shapedends, each said end being suitably located and of suflicient axiallength'a-nd radial width tho not of sufficient circumferential thicknessto compose a commutator segment, assembling the loops in the core,forming a cylindrical ring by placing the ends of the loopscircumferentially adjacent, pairs of ends in electrical contact being ofsuflicient thickness for commutator seg ments, and binding the membersof each pair together to compose segments and the segments together tocompose a commutator.

2. The method of making an armature which consists of providing a corehaving rectangular winding slots, providing rectangular wireof'such-size that two wires laced one radially above the other. will 'suStantially fill one said slot, cutting a plurality of v len hs of saidwire, each said length being su cient to compose a turn of the winding,bending the lengths into loo s of suchform that each has a conductor aradapted to occupy the outer half of a core slot-and another conductorbar adapted to occupy the inner half of a core slot, striking the freeends of the conductors in a die to form wed shaped lugs havinglongitudinal grooves-"m thelr sides, each said'lug being suitablylocated and of sufiicient axial length and radial width but of-only halfthe circumferential thicknessfor a commutator segment, assembling theloops in the core slots with the free ends in circumferentially adjacentlayers forming a cylindrical ring, holding pairs of :5 said ends inelectrical contact to com commutator segments while holdin said segmentsspaced apart, and molding insulating materia between and around theconductor ends and into the said longitudinal grooves m to composesegments of the said pairs and a commutator of the said so ents.

3. The method of making an armature 'which consists of roviding aplurality of loops, each integra y comprising'a turn of 5 the windinghavi half of acommutator segment at each en assembling th'loops m acore, placing the structure in a mold,applying pressure to the twohalves of each aegment to hold them together in electrical contact,holding said segments spaced apart one from another, and moldingmsulating mate- '-rial thruand about the structure to com segments ofthe said halves and a commutator of the said segments. v naiietestimonywhereof. I hereunto my viNcEN'r a. new,

